Reduction of iron ores



y 3, 9 A. TQCAPE ETAL I 2,444,915

REDUCTION OF IRON ORES Filed April 21, 1944 PERCENT OF TOTAL OXYGEN REMOVED 5 5 8 TEMPERATURE IN DEGREES CENTIGRADE.

INVENTORS. ARTHUR T CAPE AND CHARLES ,FOERSTER.

Patented July 13, 1948 REDUCTION OF mos ones Arthur T. Cape, Columbus, and Charles V.

Foerster, Canton, Ohio, assignors to Coast Reduction, Inc., Watsonville, Calif., a corporation of Delaware Application April 21, 1944, Serial No. 532,054

4 Claims. 1

This invention relates, as indicated, to the reduction of iron ores by means of gaseous reducing agents, but has reference more particularly to the reduction of magnetite and ores in which magnetite is a predominating constituent.

In United States Patent No. 2,379,423, there is disclosed a method of effecting the reduction of iron ores by means of coke oven and other gases relatively high in hydrogen, at temperatures of from about 900 F. to about 1350 F. It is stated in said patent that Within this rather low temperature range, the carbon monoxide in the gas decomposes to form carbon dioxide and carbon, and that it is essential for this reason to maintain the carbon monoxide content of the gas below a predetermined value. It is also stated -that at temperatures above about 1350", the

methane in the gas begins to decompose, necessitating the observance of precautions in the use of the upper portion of the above reducing temperature range.

We have discovered that by mixing the ore, prior to reduction, with a small quantity of a compound selected from the group consisting of sodium, potassium, and barium, especially'the carbonates of these elements and more particularly sodium carbonate, and in such a manner as to form on all of the lumps or particles of the ore, a layer of discrete particles or discontinuous areas of such compound that the rate of reduction can be greatly accelerated, and that the temperature for the reduction can be increased to a considerable extent, i. e., up to about 1500 F., so as to obviate the decomposition of the carbon monoxide at low temperatures. At the same time, we find that the use of such compound in small quantities permits the use of increased reducing temperatures without danger of decomposing the methane in the reducing gas.

More specifically, we have found that these results can be attained by using quantities of such compounds which are so small as to involve little or virtually no increase in the cost of reduction. These quantities may vary from 0.25% to 2.00% by weight of the ore to be reduced. In most cases, however, about 1% will be used.

While most compounds of the above-named elements have been found suitable for the purpose, we have secured excellent results through the use of carbonates of the elements, and more especially sodium carbonate.

The compound is intimately mixed with the ore, and the mixture then caused to traverse a reducing furnace, preferably in countercurrent I relation to the reducing gas,.which may be pure hydrogen, coke oven gas, retort coal gas, oil gas,

or other gas relatively high in hydrogen. Mloreeach and every grain must be covered with the compound.

(3) To obtain the maximum effect, the particles of the compound must be of a size comparable with that of chemically-precipitated materials. In otherwords, coarse grains or particles cannot be used.

(4) An especially desirable method of forming Q the layer is to mix the very finely divided compound with the ore, and then wet the ore so that the surfaces of theore particles are covered with the compound. When the moisture is subsequently evaporated, the compound will be found to be spread over the surfaces of the ore particles in the desired manner.

(5) The coating or layer of the compound on the ore particles or grains must not be continuous since this has been found to completely stop thereaction. The use of too large a quantity of the compound,.i. e., inexcess of 2%, is therefore to be avoided, since large quantities tend to form such continuous layers. The importance of this factor is illustrated by experiments with a single crystal of the ore at a reducing temperature in a stream of hydrogen. In one case, a crystal was coated on a portion of one face thereof with a thick (continuous) layer of sodium carbonate. It was found that the reduction under the layer was only slight, but that at the edges of the layer, substantial reduction had taken place. In the other case, a thin (discontinuous) layer of sodium carbonate had been applied to a portion of one face of the crystal, and it was found that uniform reduction had taken place under all portions of such layer.

(6) Sodium carbonate tends to make the grains of ore stick together, particularly after the reduction, but barium carbonate does not cause such sticking. For practical purposes, therefore,"

mixtures of sodium and barium carbonate can be eifectively used, or mixtures of sodium carbonate with alumina, finely divided magnesia, or calcium carbonate, etc.

(7) Water in as small amounts as possible should be present in the admixture of ore grains and the compqundintquestion, since if the oreis. excessively wet at the time it is introduced into the reducing furnace, an undesirable condensa tion of water from the reducing gas will occur.-

In any event, the compound should notbe mixed with ore which is unduly wet. Stated in another way, the temperature and moistureconditions in: the reduction system must be maintained so as toprevent precipitation of moisture or water vaporfrom the gas onto the ore, which would, in turn,

cause the compound to be washedtgofiigtheiore of-'-50% at about- 70W 0., and then rising slowlyagain at temperaturesabove'TOO C. In the case where {about 1% sodiumcarbonate has been mixediwiththe magnetite, the degree of reduction -rises *rapidly until a temperature-of about 60 0 has been attained, but-at higher temperatures,- thereis no falling-ofiin the degree of reduction?" Instead; the degree-pf reduction increases by minute increments, asymptotically apreaching 100% -asa maximum.

Although the process hasbeen described as applicable' tothe-reduction -of-iron ores generally by means of gaseous reducing-agents, its use is-par-- ticularly advantageous in the treatment of mag.- net'ite, the results describedwith reference to the abovle curve having been attained on-Iyin the case of rnagnetiter In-the treatment of hematite, the V result isnot as pronounced as described in connection' with said curve;-

"we claimc 1-. -The method of reducing iron ore which con-- sists in mixing intimately with the-ore particles a carbonate of the group consistingof sodium, po-

tassiumg and barium; -the amount of such.carbonatebeing from .25 to 2%-'-by-;weig-ht--of the V ore; wetting the ore-carbonate mixture-sothat when the moisture is subsequently evaporated the J surfaces of the ore particles are covered with a layer of discrete particles or discontinuous areas of the carbonate, and then subjecting the coated ore particles to the action of a. gaseous reducing agent.

2. The method of reducing iron ore which consists in mixing sodium carbonate intimately with the-ore particles, the amount of sodium carbonate being from 25% to 2% by weight of the ore, wetting the ore-carbonate mixture so that when the moisturenissubsequently evaporated the surfaces of the ore particles are covered with a, layer of discrete.=-particles-or discontinous areas of the carbonate, and then= subjecting the coated ore particles to; the action of a gaseous reducing agent.

3.,The methodlofreducing iron ore which consists immixing intimately with the ore particles a carbonateof the group consisting of sodium, potassium, andbarium, the amount of such carbohate being -from-.25% to2% by weight ofthe ore, said-"mixture having incorporated therein water in sufficient quantity such that when it is" subsequently"evaporated the surfaces of the ore particles ,are coveredwith a layer of discrete par-- ticles, ordis'continuous areas of the carbonate, and thenhsubje'cting the coated ore-particlesto the action'of a gaseous reducing agent.-

4; The method of reducing ironore which'con- I sistsin mixing sodium carbonate intimately-withthe oreparticles, the amount of sodium carbonatebeing from ,25%' to 2 %"by,we ight of the'ore; said mixture 'having incorporated therein-r water in suflicient qu antity such that when" it :is subse-' quently evaporated the, surfaces of'the ore par;-

ticles are, coveredwith a layer of discrete parti cles or discontinuous areas ,of the -carbonate;and*

then subjecting the coated oreparticles to the action of a gaseous reducing agent:

T ARTHURTCAPEr CHARLES V. FGERJSTERz'.

REFERENGES CITE lhe following references, are of record in,.the larpftth sa en nrrnn 'STATESPATENTS- OTHER REFERENCES Industrial, and ,Engineering Chemistry vol. 24,11, No, l2, pages,l39jl ,to. 1 400.4 

